Thanks to everyone for your positive feedback. My CIS gurus pointed out that there is I could have improved the write up in one area, how to be sure the center stainless steel plate is properly oriented to the top and base of the fuel distributor. This attached picture provides a big HINT.

I created an addendum to the article and sent that to everyone that already asked for the article and created a new article verion and am now sending that for new requests. If you recieved the orginal article and didn't get an addendum, drop me a line and I'll send it (or the new version).

Forgive my ignorance, but what would be a sign that the fuel distributor needs rebuilt? I'm probably going to be a shark owner within three weeks or so, and I'm trying to research any PM type stuff I need to do, especially with the CIS.

IMHO, it would be last thing to do, depending on symptoms. Mostly likely if car has sat unused for a long time, and if the system pressure is wrong, poor delivery at injectors, etc. Start at the fuel filter, both internall and external, pump check valve, accumulator. Get the injectors cleaned, run some Techron through it. Measure the pressures. Get a copy of Ben Watson, and a gauge set from Whitneys. Pray your WUR is good - if not flush with cleaner back and forth. I get misfires a couple of times a year, and my wrench says that means there is dirt in the distributor clogging a slit - clears if I relieve pressure by opening any fitting. At this frequency, its not worth fixing yet.
jp 83 Euro S AT 48k, BTDT.

So what would CIS PM consist of on an Euro '83? I use techron in my Audi and 4Runner every oil change anyway, would you need to pull the injectors and clean them with something else? Also, would a car that's grumpy when it's cold probably be a symptom of a WUR problem? I'm trying to get a good idea of CIS and avoiding problems with it, are there any good web tutorials on it?

The operation of the distributor is linear. If the car doesn't run well when cold but runs OK when warm look elsewhere (cold start system). Symptoms of a bad distributor are lean or rich running on one or more injectors when the system and control pressures check OK and AF adjustments won't bring it into spec. Also dumping of fuel into the lower plenum is a postive sign your distributor need rebuilt.

Get a copy of Ben Watson, he has a good list of problems in CIS, and what to look at for each. Grumpy when cold (ie rough, poor response) sounds like high control pressure producing too lean a mixture for the temp. You MUST check the pressures before going anywhere else, and localize the cause of the problem. On my car, it NEVER misses a beat stone cold - I can get up a sharp hill within a minute of firing up. CIS is VERY intolerant of air leaks (ie vacuum hoses etc) also.
PM as such - fuel filter regularly, Techron before each oil change is about it. DOnt let it stand for long periods unused.
jp 83 Euro S AT 48k

jpitman2 - If you can find those sizes, I'd be interested too. So far, they have escaped me.

BTW - the plunger piston is married to the plunger body with very, very close tolerances. Do NOT drop it - if you do, the fuel distributor is likely ruined. Do not sand it or emery-cloth it. It cannot
be "swapped" into another fuel distributor. You cannot take two fuel distriubutors and make one.

Carl,
My first source says he can do these in Viton (high temp stuff), almost no problem. There is no 27.5 diameter ring - 27 or 28mm ID. Just a $2 mincharge per line item. Big deal.
SO question is, what exactly are the sizes? Some care needed here...as I read Rich's note:-